Abrasion caused by high temperature impact clinker dust and chemical influences causing kiln burners to not reach expected lifespan. This influences production and frequent repairs with high cost on burner refractory material.
Mehran Ceramics the leader in refractory installations and pre-cast products in the cement and lime industry has developed a method to line kiln burner pipes that will exceed lifespan of 12 months on refractory. It is common for cement producers to lose refractory life on their burners within 6 months.
Refractory suppliers around the world have tried many different methods and techniques ranging from anchor types, spacing and high abrasion materials. Mehran Ceramics had the opportunity to work with many refractory suppliers over the years, with experience to different lining procedures.
The Group’s Precast Division has taken a different approach irrespective of the refractory material, anchor spacing and expansion allowance present. Mehran Ceramics believes that the key in extending burner lifetime lies in a common procedure that consists of the elements, discussed below.
The installation of refractory material gets installed incorrectly therefore is it important to allow the correct mixing times, right amount of water and sufficient vibrating frequencies. The anchor welding procedure is just as important for the burner refractories as the correct mixing procedure.
This is the method that should be followed on any kiln refractory burner and is common to all installation procedures, but the best refractory lining with the best anchors possible would not resolve burner lifetime issues. Mehran Ceramic's answer for the success on burner lifetimes lies within the heat up procedure. What is required is a precast facility that has the capacity to dry out complete burner pipes and not just the burner tip. The process requires increasing the temperature by 10 degrees Celsius per hour till it reaches a 100 degrees Celsius. Thereafter holding the temperature at a 100 degrees Celsius for 16 Hours, and then increasing the temperature by 10 degrees Celsius per hour until it reaches 450 degrees Celsius. Next, maintain the temperature at 450 degrees Celsius for a minimum of 12 hours. This allows you to get rid of all excess moist and water within the refractory lining. The second part of the manufacturing process is cooling the burner down by gradually decreasing the temperature with 10 degrees Celsius per hour from 450 degrees Celsius to room temperature. This will eliminate cracking on refractory lining caused by thermal shock.
More innovative precast techniques on refractory lining in cement and lime plants could be gathered from Mehran Ceramics. Visit our website on www.mehranceramics. com
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